### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-54-0049**  Original Issue: July 16, 2007 Revision 2: July 27, 2011 ATA System: 5451 **SUBJECT:** NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification - Rolls Royce RB211-535E Engines Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 1 of 78 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 2 of 78 **BOEING SERVICE BULLETIN 757-54-0049**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 21 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 25 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 26 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 3 of 78 **BOEING SERVICE BULLETIN 757-54-0049**FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . 54 FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . 57 FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 FIGURE 13: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . . . . . . . . . 72 FIGURE 14: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION [Group 1, Configuration 1]. . . . . . . . . . . . . . . . . . . . . . . . . . 75 APPENDIX A: AFT HINGE FITTING FASTENER STACKUP. . . . . . . . . . . . . . . . . . . . . . . . 78

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 4 of 78 **BOEING SERVICE BULLETIN 757-54-0049**

### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Revision Transmittal Sheet**  **Number: 757-54-0049** Original Issue: July 16, 2007 Revision 2: July 27, 2011 ATA System: 5451 **SUBJECT:** NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification - Rolls Royce RB211-535E Engines This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on the airplane(s) changed in accordance with Revision 1 of this service bulletin. Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-13-20 is related to this service bulletin. **REASON FOR REVISION** This revision is sent to inform operators that an aft hinge fitting designed with the trim already in it, is being made available as an option to trimming an existing or new hinge fitting. These sections were changed: 1. Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added optional 311N5148-4 Hinge Fitting and optional replacement shim. 2. Paragraph 3.A., General Information, updated the general notes. 3. Paragraph 3.B., Work Instructions, Part II - Inspection, added optional 311N5148-4 fitting to step 1.a, 1.e.(2)(b), 2.a., and 2.e.(2)(b). 4. Paragraph 3.B. Work Instructions, Part III - Preventive Modification, added option to use a new 311N5148-4 fitting designed with the trim already in it, under Step 4.b. Option 2, substeps (2) and (5). 5. Figures 13 and 14, added optional 311N5148-4 fitting to step 6, added footnote (c) with option to use BMS 5-95 instead of BMS 5-45, and added footnote (d) with option to install a replacement shim. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 5 of 78**REVISION HISTORY** July 16, 2007 Original Issue: September 23, 2009 Revision 1: July 27, 2011 Revision 2:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 6 of 78 **BOEING SERVICE BULLETIN 757-54-0049**

### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 757-54-0049** Original Issue: July 16, 2007 Revision 2: July 27, 2011 ATA System: 5451 **SUBJECT:** NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification - Rolls Royce RB211-535E Engines BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** You cannot make the changes given in this service bulletin unless the changes given in Service Bulletin 757-54-0015 R3 are made prior to or concurrent with this service bulletin. The 757-54-0015 service bulletin replaced an older aft hinge fitting and attachment bolts with the current part numbers on airplanes line numbers through 241. The changes given in Service Bulletin 757-54-0015 were made on airplanes after line number 241, before delivery. **BACKGROUND** This service bulletin gives instructions to do a detailed inspection and preventive modification on the thrust reverser aft hinge fittings, and hinge fitting attachment bolts. Attachment bolts have been reported to fail at the thrust reverser aft hinge fittings. The hinge has integral fail-safe features, but loss of the entire four bolt pattern constitutes complete loss of the load path. Loss of the load path could result in the departure of the thrust reverser from the airplane which could result in damage to the airplane and hazards to persons or property on the ground. Boeing has received 13 reports of 14 separate incidents of bolt failure at the thrust reverser aft hinge fittings. All of the reported incidents occurred on airplanes with Rolls Royce RB211-535E engines. Of the 14 incidents there were 9 hinges with 1 out of 4 bolts failed, 2 hinges with 2 out of 4 bolts failed, and 3 hinges with 3 out of 4 bolts failed. The possible causes of the bolt failure can be attributed to high operational loads, contact loads caused by possible interference between the thrust reverser hinge and the hinge beam, and the 4 attachment bolts are installed with washers that can ride the radius of the hinge fitting spotface. As a part of a service bulletin validation program, this change was completed on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 before the initial release of this service bulletin. The change completed on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 is equivalent to the initial release of this service bulletin. Boeing Service Related Problem (SRP) 757-SRP-54-0098 is related to this service bulletin. **ACTION (PRR 55029-R)** (PRR 54530-267RS)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 7 of 78Inspections: Get Access to the thrust reverser aft hinge fittings. Do a detailed inspection of the aft hinge fittings and the eight attachment bolts for signs of damage. If any damage to the aft hinge fitting and/or attachment bolts is found, the damage must be corrected before further flight and the preventive modification must be scheduled. For Group 1, Configuration 2 airplanes, do a detailed inspection of washer stackup. If the stackup is incorrect, the washers must be removed and reinstalled. Preventive Modification: Operators may do the preventive modification. After the preventive modification is accomplished it is no longer necessary to do the repeat inspections shown in this service bulletin. Get Access to the thrust reverser aft hinge fittings. Remove the thrust reverser C-ducts. Trim the aft hinge fitting lugs or install a fitting designed with the trim already in it, to clear possible contact with the hinge beam. Remove the four attachment bolts on each aft hinge fitting, high frequency eddy current (HFEC) inspect the fastener holes and replace with new and improved bolts, washers and nuts. Refit thrust reversers and return airplane to a serviceable condition. The related 757-300 bulletin is Service Bulletin 757-54-0050. **EFFECTIVITY** 757-200/ 200CB/ 200PF airplanes with Rolls Royce RB211-535E engines. Refer to Paragraph 1.A.1. **COMPLIANCE** Refer to Service Bulletin Paragraph 1.E for compliance. Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2008-13-20 is related to this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of October 17, 2003. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER** Refer to Service Bulletin Paragraph 1.G Manpower. **MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 8 of 78 **BOEING SERVICE BULLETIN 757-54-0049**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 9 of 78 **BOEING SERVICE BULLETIN 757-54-0049**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 10 of 78 **BOEING SERVICE BULLETIN 757-54-0049**

BLANK PAGE

### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-54-0049**  Original Issue: July 16, 2007 Revision 2: July 27, 2011 ATA System: 5451 **SUBJECT:** NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification - Rolls Royce RB211-535E Engines BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. Refer to PRR 54530-267RS and PRR 55029-R for data about this change.
**DESCRIPTION CONFIGURATION**  **GROUP** 757-200/ 200CB/ 200PF Airplanes, with Rolls Royce RB211-535E engines. - 1
Airplanes that have not been modified in accordance with the original issue of this service bulletin. 1
Airplanes that have been modified in accordance with the original issue of this service bulletin. 2

Airplane Models: 757-200, 757-200CB, 757-200PF **Group Variable Number**  1 NA002 - NA028 1 NA194 - NA199 1 NA237 - NA239

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 11 of 78**Group Variable Number**  1 NA301 - NA305 1 NA341 - NA352 1 NA392 - NA399 1 NA401 - NA408 1 NA441 - NA447 1 NB021 - NB023 1 NB036 - NB041 1 NB051 - NB053 1 NB061 - NB073 1 NB079 1 NB131 - NB148 1 NB161 - NB162 1 NB201 - NB204 1 NB221 - NB228 1 NB230 1 NB236 1 NB239 1 NB261 - NB267 1 NB291 - NB299 1 NB301 - NB302 1 NB311 1 NB321 - NB331 1 NB421 - NB438 1 NB446 1 NB451 - NB454 1 NB501 - NB523 1 NB561 1 NB571 1 NB581 - NB583 1 NC058 - NC062 1 NC936 - NC950 1 NC971 - NC974 1 ND001 - ND007

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 12 of 78 **BOEING SERVICE BULLETIN 757-54-0049 Group**  **Variable Number** 1 ND011 - ND059 1 ND111 - ND113 1 ND161 - ND199 1 ND201 - ND203 1 ND221 - ND225 1 ND241 - ND248 1 ND301 - ND322 1 ND401 1 ND891 1 ND895 1 NJ001 - NJ004 1 NJ031 - NJ032 1 NN001 - NN002 1 NN051 - NN052 1 NS601 - NS616 1 NT001 - NT009 1 NT201 - NT202 1 NT231 - NT234 1 NT237 - NT240 1 NT242 1 NT245 - NT248 1 NT281 - NT289 1 NT381 - NT386 1 NT401 - NT409 1 NT411 - NT412 1 NT426 - NT427 1 NT431 - NT432 1 NT436 - NT438 1 NT446 1 NT731 - NT769 1 NT861 - NT862 1 NT901 - NT916 1 NT971 - NT985

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 13 of 78 **BOEING SERVICE BULLETIN 757-54-0049**2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use. **B. Concurrent Requirements** You cannot make the changes given in this service bulletin unless the changes given in Service Bulletin 757-54-0015 R3 are made prior to or concurrent with this service bulletin. The 757-54-0015 service bulletin replaced an older aft hinge fitting and attachment bolts with the current part numbers on airplanes line numbers through 241. The changes given in Service Bulletin 757-54-0015 were made on airplanes after line number 241, before delivery. **C. Reason** This service bulletin gives instructions to do a detailed inspection and preventive modification on the thrust reverser aft hinge fittings, and hinge fitting attachment bolts. Attachment bolts have been reported to fail at the thrust reverser aft hinge fittings. The hinge has integral fail-safe features, but loss of the entire four bolt pattern constitutes complete loss of the load path. Loss of the load path could result in the departure of the thrust reverser from the airplane which could result in damage to the airplane and hazards to persons or property on the ground. Boeing has received 13 reports of 14 separate incidents of bolt failure at the thrust reverser aft hinge fittings. All of the reported incidents occurred on airplanes with Rolls Royce RB211-535E engines. Of the 14 incidents there were 9 hinges with 1 out of 4 bolts failed, 2 hinges with 2 out of 4 bolts failed, and 3 hinges with 3 out of 4 bolts failed. The possible causes of the bolt failure can be attributed to high operational loads, contact loads caused by possible interference between the thrust reverser hinge and the hinge beam, and the 4 attachment bolts are installed with washers that can ride the radius of the hinge fitting spotface. As a part of a service bulletin validation program, this change was completed on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 before the initial release of this service bulletin. The change completed on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 is equivalent to the initial release of this service bulletin. Revision 1: This revision is sent to change the Work Instructions for Part III - Preventive Modification, and the associated figures, to allow the option of doing the Part III - Preventive Modification on just the hinges that are damaged, and allow continued repeat inspections on the hinges that are undamaged. This revision also corrects the names of the different washers (special washer, countersunk washer, plain washer) used in Figure 11 and Figure 12. Revision 2: This revision is sent to inform operators that an aft hinge fitting designed with the trim already in it, is being made available as an option to trimming an existing or new hinge fitting. Changes appearing in Revision 1 of this service bulletin include: — Paragraph 1.E., Compliance - Footnote and Damage Tolerance note added. — Paragraph 3.B., Work Instructions, Part III-Preventive Modification - Added steps 4, 5. Added Caution note to step 3. — Figures 1-12 were modified to include a footnote adding flexibility in inspecting and modifying the hinges.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 14 of 78 **BOEING SERVICE BULLETIN 757-54-0049**— Figures 13 and 14 were modified to include a flag note stating that quantities could be halved if only one hinge is removed/installed on either strut. — The Fastener Tables in Figures 11 and 12 were modified to correct the names of washers and to add words that clarify the washer orientation. — Added note to Figures 5, 6, 9 and 10, to clarify that you remove one bolt at a time, replace it with a new bolt, and then go to the next bolt. — Added a second configuration for those airplanes that have completed the original issue of this service bulletin, to inspect for washer stackup in Figures 11 and 12. Added Appendix A to show correct fastener stackup. — Added flexibility to install a new aft hinge fitting if heat damage is found after trimming. — Added ammonium persulfate in addition to Nital to use for inspecting for heat damage. — Replaced BMS 3-24 grease with BMS 3-33 grease. — Changed torque reference from SOPM 20-50-01 to BAC5009. — Changed Figures 13 and 14 to interim installation of existing fittings and removed torque specifications in footnotes. Changes appearing in Revision 2 of this service bulletin include: – Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added optional 311N5148-4 Hinge Fitting and optional replacement shim. – Paragraph 3.A., General Information, updated the general notes. – Paragraph 3.B., Work Instructions, Part II - Inspection, added optional 311N5148-4 fitting to step 1.a, 1.e.(2)(b), 2.a., and 2.e.(2)(b). – Paragraph 3.B. Work Instructions, Part III - Preventive Modification, added option to use a new 311N5148-4 fitting designed with the trim already in it, under Step 4.b. Option 2, substeps (2) and (5). – Figures 13 and 14, added optional 311N5148-4 fitting to step 6, added footnote (c) with option to use BMS 5-95 instead of BMS 5-45, and added footnote (d) with option to install a replacement shim. Boeing Service Related Problem (SRP) 757-SRP-54-0098 is related to this service bulletin. **D. Description** Inspections: Get Access to the thrust reverser aft hinge fittings. Do a detailed inspection of the aft hinge fittings and the eight attachment bolts for signs of damage. If any damage to the aft hinge fitting and/or attachment bolts is found, the damage must be corrected before further flight and the preventive modification must be scheduled. For Group 1, Configuration 2 airplanes, do a detailed inspection of washer stackup. If the stackup is incorrect, the washers must be removed and reinstalled. Preventive Modification: Operators may do the preventive modification. After the preventive modification is accomplished it is no longer necessary to do the repeat inspections shown in this service bulletin. Get Access to the thrust reverser aft hinge fittings. Remove the thrust reverser C-ducts. Trim the aft hinge fitting lugs or install a fitting designed with the trim already in it, to clear possible contact with the hinge beam. Remove the four attachment bolts on each aft hinge fitting, high frequency eddy current (HFEC) inspect the fastener holes and replace with new and improved bolts, washers and nuts. Refit thrust reversers and return airplane to a serviceable condition. The related 757-300 bulletin is Service Bulletin 757-54-0050.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 15 of 78 **BOEING SERVICE BULLETIN 757-54-0049**Revision 1: More work is necessary on airplanes changed as shown in the original issue of this service bulletin. Washer stackup should be inspected for the correct installation sequence. If the installation is found to be incorrect, the nut(s) and bolt(s) must be removed and the washers reinstalled. Revision 2 : No more work is necessary on airplanes changed in accordance with Revision 1 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 415, 416, 425, 426, 431, 441 757-200, 757-200CB, 757- 200PF **E. Compliance** Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2008-13-20 is related to this service bulletin. **Table 1(Group 1, Configuration 1): Inspection of the two thrust reverser aft hinge fittings and eight fitting attach bolts on each engine for contact and damage** 
**Re peat** **Inter val**  **(Not to Ex**  **ceed) Compliance**  **Time Action**  **Condition**

3000 Flight Cycles (a) Within 3000Flight Cycles after the original issue date ofthis service bulletin Do a Detailed Inspection of the two thrust reverser aft hinge fittings and eight fitting attach bolts on each engine as given in Accomplishment Instruction 3.B.,Part II Group 1, Configuration 1 Airplanes

- Before Further Flight Replace the aft hinge fitting and do Preventive Modification as given in Accomplishment Instruction 3.B., Part III (c) Cracked or broken aft hinge fitting

- Before Further FlightApply surface finish as given in Accomplishment Instruction 3.B., Part II Option 1 Aft hinge fitting shows contact damage less than 0.005 inch depth

- Within 3000Flight Cycles after surface finish is applied Do Preventive Modification as given in Accomplishment Instruction 3.B., Part III (c)

- Before Further Flight Do Preventive Modification as given in Accomplishment Instruction 3.B., Part III (c) Option 2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 16 of 78 **BOEING SERVICE BULLETIN 757-54-0049 Table 1(Group 1, Configuration 1): Inspection of the two thrust reverser aft hinge fittings and eight fitting**  **attach bolts on each engine for contact and damage**
**Re peat** **Inter val**  **(Not to Ex**  **ceed) Compliance**  **Time Action**  **Condition**

- Before Further Flight Do Preventive Modification as given in Accomplishment Instruction 3.B., Part III (c) Aft hinge fitting shows contact damage greater than or equal to 0.005 inch depth

- Before Further Flight Do Preventive Modification as given in Accomplishment Instruction 3.B., Part III (c) Option 1 Damaged attach bolt

- Before Further Flight Do a High Frequency Eddy Current (HFEC) Inspection of the attach bolt hole as given in Accomplishment Instruction 3.B., Part II Option 2

- Before Further Flight Replace bolt as given in Accomplishment Instruction 3.B., Part II No crack was found inattach bolt hole as a result of HFEC inspection

- Within 3000Flight Cycles after bolt replacement Do Preventive Modification as given in Accomplishment Instruction 3.B., Part III (c)

- Before Further Flight Do Preventive Modification as given in Accomplishment Instruction 3.B., Part III(c) A crack was found inattach bolt hole as a result of HFEC inspection

- Before Further Flight If any crack is found in aft hinge fitting, install new aft hinge fitting or contact Boeing for repair instructions and repair as given in Accomplishment Instruction 3.B., Part III 0.4688 inch nominal lower fastener hole with crack OR OR If any crack is found in the strut, contact Boeing for repair instructions and do the repair. 0.5312 inch nominal upper fastener hole with crack

- Before Further Flight Install new aft hinge fitting as given in Accomplishment Instruction 3.B., Part III. Aft hinge fitting is found to have heat damage after trimming. OR Contact Boeing for repair instructions and do the repair. (a) Accomplishment of the Preventive Modification on a hinge as given in Accomplishment Instruction 3.B., Part III terminates the requirement to do repeat inspections on that hinge. (b) Not Used

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 17 of 78 **BOEING SERVICE BULLETIN 757-54-0049 Table 1(Group 1, Configuration 1): Inspection of the two thrust reverser aft hinge fittings and eight fitting**  **attach bolts on each engine for contact and damage**
**Re peat** **Inter val**  **(Not to Ex**  **ceed) Compliance**  **Time Action**  **Condition**

(c) Preventive Modification is required for hinges with damage and is optional for hinges without damage.Repeat inspections are required on all unmodified hinges until the Preventive Modification, as given in Accomplishment Instruction 3.B, Part III, is accomplished. **Table 2 (Group 1, Configuration 2): DETAILED INSPECTION OF FASTENER STACKUP ON AFT HINGE FITTINGS FOR AIRPLANES THAT HAVE BEEN MODIFIED IN ACCORDANCE WITH THE**  **ORIGINAL ISSUE OF THIS SERVICE BULLETIN Repeat Interval (Not**  **to Exceed) Compliance Time**  **Action Condition** 

- Within 3000 flight cy- cles after the Revision 1 date of this Service Bulletin. Do a one-time detailed inspection of fastenerstackup as given in Accomplishment Instruction 3.B., Part IV. Group 1, Configuration 2 airplanes

- Before Further Flight Reinstall washers cor-rectly as given in Accomplishment Instruction 3.B., Part IV. Washers found to beinstalled incorrectly after doing one-time detailed inspection. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the accomplishment of the applicable inspections, investigative and corrective actions with the corresponding compliance times specified in Tables 1 and 2 under paragraph 1.E., "Compliance," of Service Bulletin 757-54-0049, Revision 2, as an AMOC to the accomplishment of the applicable inspections, investigative and corrective actions with the corresponding

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 18 of 78 **BOEING SERVICE BULLETIN 757-54-0049**compliance times specified in paragraph 1.E., "Compliance," of Service Bulletin 757-54-0049, dated July 16, 2007, as required by paragraphs (f) and (h) of AD 2008-13-20. When this service bulletin specifies contacting Boeing for repair instruction, the repair instructions must be approved by the FAA in accordance with paragraph (k) of the AD. All provisions of AD 2008-13-20 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. Group 1 Configuration 1 - INSPECTION MANHOURS: **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**
1.0 2.0 2 Open Access 0.5 1.0 2 Figure 1 0.5 1.0 2 Figure 2 1.0 2.0 2 Close Access 3.0 6.0 TOTAL FOR EACH AIRPLANE Group 1 Configuration 1 - MODIFICATION MANHOURS: **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**
5.25 10.5 2 Open Access 4.0 8.0 2 Figure 3 4.0 8.0 2 Figure 4 2.5 5.0 2 Figure 5 2.5 5.0 2 Figure 6 0.5 1.0 2 Figure 7 0.5 1.0 2 Figure 8 2.5 5.0 2 Figure 9 2.5 5.0 2 Figure 10

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 19 of 78 **BOEING SERVICE BULLETIN 757-54-0049 Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 
0.5 1.0 2 Figure 11 0.5 1.0 2 Figure 12 5.25 10.5 2 Close Access 30.5 61 TOTAL FOR EACH AIRPLANE
**NOTE:**The total man-hours is dependant on the method of modification. The total man-hours shown are for modification of the aft hinge fitting on the airplane. Group 1, Configuration 2 - DETAILED INSPECTION (of Fastener Stackup) MANHOURS: **Elapsed Hours Task-Hours**  **Number of Persons Task**  1.0 2.0 2 Open Access 1.0 2.0 2 Inspect 1.0 2.0 2 Close Access 3.0 6.0 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Engineering Change Memo PRR-54530-267RS and PRR-55029-R. b. 757 Aircraft Maintenance Manual (AMM) 24-41-01, 29-11-25, 71-00-02, 78-31-00, 78-31-10, 78-31-20. c. 757 Non-destructive Testing (NDT) Manual, Part 6, 51-00-16, Part 6, 51-00-17. d. Boeing Drawing 65-88700. e. Boeing Tooling Drawing MIT012N8549-2. f. Service Bulletin 757-54-0015 "NACELLES/PYLONS - NACELLE STRUT - THRUST REVERSER HINGE FITTING REPLACEMENT". g. Service Bulletin 757-54-0050 "NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Hinge Fitting Modification - Rolls Royce RB211-535E Engines".

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 20 of 78 **BOEING SERVICE BULLETIN 757-54-0049**h. Standard Overhaul Practices Manual (SOPM) 20-10-01, 20-10-02, 20-10-03, 20-30-03, 20-42-10, 20-44-01, 20-50-01, 20-50-10, 20-50-19 i. Boeing Service Letter 757-SL-51-022 j. Federal Aviation Administration (FAA) Airworthiness Directive 2008-13-20 2. Data supplied with this Service Bulletin: a. Drawings:
**ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- - 1 Miscelaneous Tool - Hinge Assembly Aligning Tool MIT012N8549-2

- - 1 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. **K. Publications Affected** 1. Publications: **Chapter-Section Publication**  54-51 757 Illustrated Parts Catalog 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.
**L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 21 of 78 **BOEING SERVICE BULLETIN 757-54-0049**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 22 of 78 **BOEING SERVICE BULLETIN 757-54-0049**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, and Paragraph 2.D., Parts Necessary to Change Spares, as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.
**Unit Price thru Oct/31/06**  **ROLT (Weeks)**  **QTY Date**  **Name Kit Number**  $5,276 30 10 08/25/05 TOP KIT-THRUST RE-VERSER HINGE MODIFICATION RB211-535E 012N5108-1

$5,276 30 10 09/01/05 TOP KIT-THRUST RE-VERSER HINGE MODIFICATION RB211-535E 012N5108-1

$5,276 30 10 09/09/05 TOP KIT-THRUST RE-VERSER HINGE MODIFICATION RB211-535E 012N5108-1

$5,276 30 10 09/16/05 TOP KIT-THRUST RE-VERSER HINGE MODIFICATION RB211-535E 012N5108-1

$5,276 30 10 09/23/05 TOP KIT-THRUST RE-VERSER HINGE MODIFICATION RB211-535E 012N5108-1

$5,276 30 10 09/30/05 TOP KIT-THRUST RE-VERSER HINGE MODIFICATION RB211-535E 012N5108-1

The kits/parts are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. **Reference this service bulletin and submit your purchase order by one of the methods that follow:**  1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 23 of 78 **BOEING SERVICE BULLETIN 757-54-0049 B. Industry Support Information**  Boeing warranty remedies are available for 757 airplanes in warranty as of October 17, 2003. For the initial inspection labor hour reimbursement for airplanes in warranty as of that date, send a claim to Boeing Warranty. Please note that subsequent inspections, as outlined in the MPD (Maintenance Planning Document), do not qualify for Boeing warranty remedies. If the condition described in this service bulletin is found during the initial, or MPD directed inspection, please note that the kits for airplanes in warranty as of October 17, 2003, will be supplied at no charge. Send a purchase order for the kits to Boeing Spares, and a warranty claim for labor hours to Boeing Commercial Airplanes Group - Warranty & Product Assurance Contracts. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order and any labor hour claim. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: **NOTE:**One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
**Kit 012N5108 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -1** 

- TOP KIT- THRUST REVERSER HINGE MODIFICATION RB211-535E - 012N5108-1 (b)(d)

- WASHER- SPECIAL 8 012N5108-2 (b)(d)

- WASHER- SPECIAL 8 012N5108-3 (b)(d)

- WASHER- SPECIAL 8 012N5108-4 (b)(d)

- WASHER- SPECIAL 8 012N5108-5 (a)(b)(c)(d)(e) BACB30LE7U( ) BOLT, 12 PT HEAD 8 BACB30US7K15X (a)(b)(c)(d)(e) BACB30LE7U( ) BACB30LE7U( )X BACB30LE7U( )Y BOLT, 12 PT HEAD 8 BACB30US7K15Y

(a)(b)(c)(d)(e) BACB30LE8U19 BOLT, 12 PT HEAD 8 BACB30US8K19X (a)(b)(c)(d)(e) BACB30LE8U19 BACB30LE8U19X BACB30LE8U19Y BOLT, 12 PT HEAD 8 BACB30US8K19Y

(a)(c) BACN10HR7CS SELF-LOCKING NUT 8 BACN10HR7CS (a)(c) BACN10HR8CS NUT 8 BACN10HR8CS (a)(b)(c) BACW10BP7APU WASHER, PLAIN 8 BACW10BP71APU (a)(b)(c) BACW10BP7APU WASHER, PLAIN 8 BACW10BP72APU (a)(b)(c) BACW10BP8APU WASHER, PLAIN 8 BACW10BP81ACU

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 24 of 78 **BOEING SERVICE BULLETIN 757-54-0049 Kit 012N5108**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-1** (a)(b)(c) BACW10BP8APU WASHER, PLAIN 8 BACW10BP82ACU (a) Discard the existing part. (b) This part is not used in production. (c) You cannot use the existing part to replace the new or changed part. (d) There are more parts than are necessary. (e) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700, are used to determine the part numbers used as substitutes. 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Specification**  (a) De-Soto Hi-Temperature Primer 4 Ounces Type 51 (b) Grease 4 Ounces BMS 3-33 (f) Sealant

- BMS 5-45 or BMS 5-95 (f) Primer

- BMS 10-11, Type 1 (c) (d) Hinge Fitting

- 311N5148-1 (c) (d) Hinge Fitting

- 311N5148-4 (e) Shim

- Stock 0.125 x 3.0 x 4.0 2024-T3 aluminum sheet (a) Refer to the Boeing Standard Overhaul Practices Manual SOPM 20-44-01 or 757 Structural Repair Manual, Chapter 51, for material sources. (b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) Hinge Fitting quantity depends on the number of fittings that need to be replaced. (d) 311N5148-4, aft hinge fitting designed with the trim already in it, is optional to 311N5148-1 aft hinge fitting. (e) Optional solid shim made to the same dimensions as the existing laminated shim, if removed. Quantity as required. (f) Primer applied to optional solid shim. After primer dries, fay surface sealant applied to shim. Quantity of both primer and sealant as required.

3. Parts Modified and Reidentified: The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 25 of 78 **BOEING SERVICE BULLETIN 757-54-0049 Notes**  **New Part Number Name**  **QTY Existing Part Number**  (a) (c) (d) (b) Hinge Fitting 4 311N5148-1 (a) Make the change given in this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change given in this service bulletin was made. (c) You cannot use the existing part to replace the modified part. If you use the existing part to replace the modified part you will cancel the effect of the change given in this service bulletin. (d) 311N5148-4 fitting, which is designed with the trim already in it, is interchangeable with a trimmed 311N5148-1 fitting. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. However, MIT012N8549-2 may be necessary if the aft hinge fitting is being replaced.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 26 of 78 **BOEING SERVICE BULLETIN 757-54-0049 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in 757 SRM Chapter 51 4. Use the approved fastener and process material substitutions as given in 757 SRM Chapter 51. Alternate fasteners are listed in 757 SRM Chapter 51 and Boeing Drawing 65-88700. 5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. 6. The necessary conditions for selection of clamp type and size are included in SWPM 20-10-12. If any wire bundle support clamp specified in this service bulletin does not make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted procedure to select a clamp that fits correctly. 7. If the length of any fastener specified in this service bulletin does not meet installation standards given in 757 SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in 757 SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length as given in 757 SRM Chapter 51. 8. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 27 of 78 **BOEING SERVICE BULLETIN 757-54-0049**9. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 10. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "as given in" are included in the instruction, the procedure in the Boeing document must be used. 11. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 12. Refer to Appendix A for Aft Hinge Fitting Fastener Stackup. 13. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 14. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 15. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. The removed part can be discarded if a new or serviceable part is installed. 16. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. 17. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 28 of 78 **BOEING SERVICE BULLETIN 757-54-0049 B. WORK INSTRUCTIONS**  **PART I - ACCESS** 1. Remove electrical power and electrically ground airplane. Refer to 757 AMM 24-41-01 as an accepted procedure. 2. Install thrust reverser lock out pins. Refer to 757 AMM 78-31-00 as an accepted procedure. 3. Open thrust reverser C-Ducts. Refer to 757 AMM 78-31-00 as an accepted procedure. 4. Install thrust reverser actuator hold open locks, tool number B71009. Refer to 757 AMM 71-00-02 as an accepted procedure. **PART II - INSPECTION (Group 1, Configuration 1)** 1. Do a Detailed Inspection on the number 1 engine thrust reverser aft hinge fittings and attach bolts as given in Figure 1. a. If the aft hinge fitting is cracked or broken, do PART III - Preventive modification and install a new 311N5148-1 or a new 311N5148-4 fitting. **NOTE:**The new aft hinge fitting can be positioned using tool MIT012N8549-2. See Service Bulletin 757-54-0015 for more information on how to use the tool. b. If no damage to aft hinge fittings and attach bolts is found, do one of the following: (1) Do PART V - Close Access, and do repeat inspections as given in Paragraph 1.E. Compliance until the preventive modification is accomplished. (2) Do PART III - Preventive Modification. c. If contact damage to the base metal of the thrust reverser aft hinge fittings is less than 0.005 inch deep, do one of the following options: (1) Option 1: Reapply surface finish, Type 51 Primer, as given in SOPM 20-44-01, and do Part III - Preventive Modification as given in Paragraph 1.E Compliance. (2) Option 2: Do PART III - Preventive Modification. d. If contact damage to the base metal of the thrust reverser aft hinge fittings is found to be equal to or more than 0.005 inches deep, do PART III - Preventive Modification. e. If damage to an attach bolt is found, do one of the following options: (1) Option 1: Do PART III - Preventive Modification. (2) Option 2: Remove the damaged attach bolt and HFEC inspect the attach bolt hole as given in 757 NDT, Part 6, 51-00-17 and 757 NDT, Part 6, 51-00-16.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 29 of 78 **BOEING SERVICE BULLETIN 757-54-0049**(a) If no crack exists install new attach bolt (either existing BACB30LE or new BACB30US) and do PART III - Preventive Modification as given in Paragraph 1.E Compliance. (b) If a crack is found do PART III - Preventive Modification and install a new 311N5148-1 or a new 311N5148-4 fitting. 2. Do a Detailed Inspection on the number 2 engine thrust reverser aft hinge fittings and attach bolts as given in Figure 2. a. If the aft hinge fitting is cracked or broken, do PART III - Preventive modification and install a new 311N5148-1 or a new 311N5148-4 fitting. **NOTE:**The new aft hinge fitting can be positioned using tool MIT012N8549-2. See Service Bulletin 757-54-0015 for more information on how to use the tool. b. If no damage to aft hinge fittings and attach bolts is found, do one of the following: (1) Do PART V - Close Access, and do repeat inspections as given in Paragraph 1.E. Compliance until the preventive modification is accomplished. (2) Do PART III - Preventive Modification. c. If contact damage to the base metal of the thrust reverser aft hinge fittings is less than 0.005 inch deep, do one of the following options: (1) Option 1: Reapply surface finish, Type 51 Primer, as given in SOPM 20-44-01, and do Part III - Preventive Modification as given in Paragraph 1.E Compliance. (2) Option 2: Do PART III - Preventive Modification. d. If contact damage to the base metal of the thrust reverser aft hinge fittings is found to be equal to or more than 0.005 inches deep, do PART III - Preventive Modification. e. If damage to an attach bolt is found, do one of the following options: (1) Option 1: Do PART III - Preventive Modification. (2) Option 2: Remove the damaged attach bolt and HFEC inspect the attach bolt hole as given in 757 NDT, Part 6, 51-00-17 and 757 NDT, Part 6, 51-00-16. (a) If no crack exists install new attach bolt (either existing BACB30LE or new BACB30US) and do PART III - Preventive Modification as given in Paragraph 1.E Compliance. (b) If a crack is found do PART III - Preventive Modification and install a new 311N5148-1 or a new 311N5148-4 fitting.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 30 of 78 **BOEING SERVICE BULLETIN 757-54-0049 PART III - PREVENTIVE MODIFICATION (Group 1, Configuration 1)**  1. Remove hydraulic power and depressurize hydraulic systems. Refer to 757 AMM 29-11-25 as an accepted procedure. 2. Remove the C-Duct hinged access door. Refer to 757 AMM 78-31-10 as an accepted procedure. **CAUTION:** THE THRUST REVERSER C-DUCTS SHOULD BE REMOVED. IF THE THRUST REVERSER C-DUCTS ARE NOT REMOVED AND YOU DO THE PREVENTIVE MODIFICATION, THEN HYDROGEN EMBRITTLEMENT CAN OCCUR AFTER THE PLATING IS APPLIED TO THE AFT HINGES. 3. Remove thrust reverser C-Ducts. Refer to 757 AMM 78-31-20 as an accepted procedure. 4. Aft Hinge Fittings that are damaged and/or have damaged bolts, must do one of the options below. Any fittings that are undamaged with undamaged bolts, and are not being re-worked per the options below, must continue to be inspected at the times shown in Paragraph 1.E Compliance, until steps 4 and 5 are accomplished. **NOTE:**Option 2 below applies to NEW and EXISTING fittings. The aft hinge fitting can be positioned during installation using tool MIT012N8549-2. MIT012N8549-2 is used in Service Bulletin 757-54-0015. Step 5 of this part may be performed prior to or concurrently with step 4 of this part. a. Option 1: (1) Trim the thrust reverser aft hinge fittings, 311N5148-1, on the number 1 engine as given in Figure 3. (2) Trim the thrust reverser aft hinge fittings, 311N5148-1, on the number 2 engine as given in Figure 4. b. Option 2: (1) Remove the thrust reverser aft hinge fittings on the number 1 engine as given in Figure 13. (2) Trim the thrust reverser aft hinge fittings, 311N5148-1, on the number 1 engine as given in Figure 3, or use a new 311N5148-4 fitting, which is designed with the trim already in it. (3) Install the thrust reverser aft hinge fittings on the number 1 engine as given in Figure 13. (4) Remove the thrust reverser aft hinge fittings on the number 2 engine as given in Figure 14. (5) Trim the thrust reverser aft hinge fittings, 311N5148-1, on the number 2 engine as given in Figure 4, or use a new 311N5148-4 fitting, which is designed with the trim already in it. (6) Install the thrust reverser aft hinge fittings on the number 2 engine as given in Figure 14.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 31 of 78 **BOEING SERVICE BULLETIN 757-54-0049**5. A trimmed fitting or a fitting designed with the trim already in it, must have larger bolts, new washers, and new nuts installed. Do the steps below which apply to a trimmed fitting or a fitting designed with the trim already in it.
a. Oversize and High Frequency Eddy Current (HFEC) Inspect the thrust reverser aft hinge fitting lower fastener holes on the number 1 engine as given in Figure 5. (1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.4688 inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions and repair the fitting. (2) If any crack is found in the strut structure and the fastener hole size is already 0.4688 inch nominal, then contact Boeing for repair instructions and do the repair. b. Oversize and HFEC Inspect the thrust reverser aft hinge fitting lower fastener holes on the number 2 engine as given in Figure 6. (1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.4688 inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions and repair the fitting. (2) If any crack is found in the strut structure and the fastener hole size is already 0.4688 inch nominal, then contact Boeing for repair instructions and do the repair. c. Install the lower fasteners in the thrust reverser aft hinge fitting on the number 1 engine as given in Figure 7. d. Install the lower fasteners in the thrust reverser aft hinge fitting on the number 2 engine as given in Figure 8. e. Oversize and HFEC Inspect the thrust reverser aft hinge fitting upper fastener holes on the number 1 engine as given in Figure 9. (1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.5312 inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions and repair the fitting. (2) If any crack is found in the strut structure and the fastener hole size is already 0.5312 inch nominal, then contact Boeing for repair instructions and do the repair. f. Oversize and HFEC Inspect the thrust reverser aft hinge fitting upper fastener holes on the number 2 engine as given in Figure 10.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 32 of 78 **BOEING SERVICE BULLETIN 757-54-0049**(1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.5312 inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions and repair the fitting. (2) If any crack is found in the strut structure and the fastener hole size is already 0.5312 inch nominal, then contact Boeing for repair instructions and do the repair. g. Install the upper fasteners in the thrust reverser aft hinge fitting on the number 1 engine as given in Figure 11. h. Install the upper fasteners in the thrust reverser aft hinge fitting on the number 2 engine as given in Figure 12. 6. Install thrust reverser C-Ducts. Refer to 757 AMM 78-31-20 as an accepted procedure. 7. Install the C-Duct hinged access door. Refer to 757 AMM 78-31-10 as an accepted procedure. **PART IV - ONE-TIME DETAILED INSPECTION FOR AIRPLANES THAT HAVE DONE THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN (Group 1, Configuration 2)**  1. Do a One-Time Detailed Inspection of the washers installed under the nuts and bolts that are installed in FIGURE 11 and FIGURE 12 to secure the aft hinge fittings to the structure. The countersunk washer must be installed under the head of the bolt with the countersink towards the bolt head and the special washer must be installed under the nut with the tapered side toward the aft hinge fitting. See Appendix A. 2. If the washers are not installed correctly, then remove the nut and bolt and reinstall the hardware as given in FIGURE 11 and FIGURE 12. **PART V - CLOSE ACCESS** 1. Remove thrust reverser actuator hold open lock tool number B71009. Refer to 757 AMM 71-00-02 as an accepted procedure. 2. Close and lock thrust reversers. Refer to 757 AMM 78-31-00 as an accepted procedure. 3. Remove thrust reverser lock out pins. Refer to 757 AMM 78-31-00 as an accepted procedure. 4. Return Airplane to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2: July 27, 2011 33 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 34 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.

**FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 35 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (d)**  **PROCEDURE NAME**  **TASK STEP**  (a) (b) Detailed Inspection Bolts Inspect 1 (c) Detailed Inspection Aft Hinge Fitting Inspect 2 (a) (b) Detailed Inspection Bolts Inspect 3 (c) Detailed Inspection Aft Hinge Fitting Inspect 4 Inspect the bolts for damage. Look for loose, fretting or broken bolts. (a) Removal of the bolts is not required for this inspection. (b) Inspect the aft hinge fitting for signs of contact and any broken or cracked fitting. (c) If only one hinge is being inspected, it is OK to skip the steps that don't apply. (d)

**FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 36 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 37 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.

**FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 38 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (d)**  **PROCEDURE NAME**  **TASK STEP**  (a) (b) Detailed Inspection Bolts Inspect 1 (c) Detailed Inspection Aft Hinge Fitting Inspect 2 (a) (b) Detailed Inspection Bolts Inspect 3 (c) Detailed Inspection Aft Hinge Fitting Inspect 4 Inspect the bolts for damage. Look for loose, fretting or broken bolts. (a) Removal of the bolts is not required for this inspection. (b) Inspect the aft hinge fitting for signs of contact and any broken or cracked fitting. (c) If only one hinge is being inspected, it is OK to skip the steps that don't apply. (d)

**FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 39 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 40 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.

**FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 41 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (h)**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) 1 Thrust Reverser Aft Hinge Fitting Clean 1 (b) 3 Trim Locations Identify 2 Refer to SOPM 20-10-01 and SOPM 20-10-02 as an accepted procedure. (e) (f) (c) 3 Thrust Reverser Aft Hinge Fitting Lug Hand Blend 3

(g) 3 Thrust Reverser Aft Hinge Fitting Deburr 4 (d) 3 Thrust Reverser Aft Hinge Fitting Inspect 5
Refer to SOPM 20-10-03as an accepted procedure. Intensity 0.014A, coverage 2.0 Shot Peen or Flap Peen Do 6

Refer to SOPM 20-42-10 an accepted procedure. Cadmium Plate to a thickness 0.0003 - 0.0005 inch. Cadmium Plate Apply 7

Refer to SOPM 20-44-01as an accepted procedure. 1 Coat Type 51 Primer Apply 8

(a) 1 Thrust Reverser Aft Hinge Fitting Clean 9 (b) 3 Trim Locations Identify 10 Refer to SOPM 20-10-01 and SOPM 20-10-02 as an accepted procedure. (e) (f) (c) 3 Thrust Reverser Aft Hinge Fitting Lug Hand Blend 11

(g) 3 Thrust Reverser Aft Hinge Fitting Deburr 12 (d) 3 Thrust Reverser Aft Hinge Fitting Inspect 13
Refer to SOPM 20-10-03as an accepted procedure. Intensity 0.014A, coverage 2.0 Shot Peen or Flap Peen Do 14

**FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 42 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (h)**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Refer to SOPM 20-42-10as an accepted procedure. Cadmium Plate to a thickness 0.0003 - 0.0005 inch. Cadmium Plate Apply 15

Refer to SOPM 20-44-01as an accepted procedure. 1 Coat Type 51 Primer Apply 16

Clean the hinge. Refer to SOPM 20-30-03 as an accepted procedure. (a) Mark the trim locations. Refer to SOPM 20-50-10 as an accepted procedure. (b) Restore the surface finish to 125 micro-inches Ra. (c) Do a detailed inspection of the trimmed area for signs of heat damage using Nital or Ammonium Persulfate as given in SOPM 20-10-02. If any damage is found, install a new aft hinge fitting or contact Boeing for additional repair instructions. (d)

Boeing recommends the use of a carbide rotary file. The part should be ground in stages, checking between stages, checking for heating after each stage. The part surface shall remain cool to the touch. (e)

Rotary burrs and files in portable hand-held motors may be used if the speed is limited to 500 rpm, maximum. Higher speed settings and/or other tools may be used provided that: (f) — The operator shall produce no discoloration. — The operator shall not cause sparking or release of molten fines. — The tools shall be applied with pressure and contact time such that no heat damage occurs. — Verify the higher speed settings and/or other tools by in-process inspection of test samples or test parts. Refer to SOPM 20-10-02 as an accepted procedure. Break all sharp edges, the minimum/maximum radius requirement (0.02 - 0.06 radius). (g) If only one hinge is being trimmed, it is OK to skip the steps that don't apply. (h)

**FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 43 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 44 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.

**FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 45 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (h)**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) 1 Thrust Reverser Aft Hinge Fitting Clean 1 (b) 3 Trim Locations Identify 2 Refer to SOPM 20-10-01 and SOPM 20-10-02 as an accepted procedure. (e) (f) (c) 3 Thrust Reverser Aft Hinge Fitting Lug Hand Blend 3

(g) 3 Thrust Reverser Aft Hinge Fitting Deburr 4 (d) 3 Thrust Reverser Aft Hinge Fitting Inspect 5
Refer to SOPM 20-10-03as an accepted procedure. Intensity 0.014A, coverage 2.0 Shot Peen or Flap Peen Do 6

Refer to SOPM 20-42-10 an accepted procedure. Cadmium Plate to a thickness 0.0003 - 0.0005 inch. Cadmium Plate Apply 7

Refer to SOPM 20-44-01as an accepted procedure. 1 Coat Type 51 Primer Apply 8

(a) 1 Thrust Reverser Aft Hinge Fitting Clean 9 (b) 3 Trim Locations Identify 10 Refer to SOPM 20-10-01 and SOPM 20-10-02 as an accepted procedure. (e) (f) (c) 3 Thrust Reverser Aft Hinge Fitting Lug Hand Blend 11

(g) 3 Thrust Reverser Aft Hinge Fitting Deburr 12 (d) 3 Thrust Reverser Aft Hinge Fitting Inspect 13
Refer to SOPM 20-10-03as an accepted procedure. Intensity 0.014A, coverage 2.0 Shot Peen or Flap Peen Do 14

**FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 46 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (h)**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Refer to SOPM 20-42-10as an accepted procedure. Cadmium Plate to a thickness 0.0003 - 0.0005 inch. Cadmium Plate Apply 15

Refer to SOPM 20-44-01as an accepted procedure. 1 Coat Type 51 Primer Apply 16

Clean the hinge. Refer to SOPM 20-30-03 as an accepted procedure. (a) Mark the trim locations. Refer to SOPM 20-50-10 as an accepted procedure. (b) Restore the surface finish to 125 micro-inches Ra. (c) Do a detailed inspection of the trimmed area for signs of heat damage using Nital or Ammonium Persulfate as given in SOPM 20-10-02. If any damage is found, install a new aft hinge fitting or contact Boeing for additional repair instructions. (d)

Boeing recommends the use of a carbide rotary file. The part should be ground in stages, checking between stages, checking for heating after each stage. The part surface shall remain cool to the touch. (e)

Rotary burrs and files in portable hand-held motors may be used if the speed is limited to 500 rpm, maximum. Higher speed settings and/or other tools may be used provided that: (f) — The operator shall produce no discoloration. — The operator shall not cause sparking or release of molten fines. — The tools shall be applied with pressure and contact time such that no heat damage occurs. — Verify the higher speed settings and/or other tools by in-process inspection of test samples or test parts. Refer to SOPM 20-10-02 as an accepted procedure. Break all sharp edges, the minimum/maximum radius requirement (0.02 - 0.06 radius). (g) If only one hinge is being trimmed, it is OK to skip the steps that don't apply. (h)

**FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 47 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 48 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.**MORE DATA (f) QTY**  **IDENTIFICATION NAME**  **TASK STEP**  2 BACN10HR7CS Nut Remove 1 (a)(g) 2 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y 2 BACW10BP7ACU Washer 2 BACW10BP7APU Washer Oversize the hole to the size listed in table 1 below. (e) 2 Fastener Hole Drill/Ream 2 As given in 757 NDT, Part 6, 51-00-17 and757 NDT, Part 6, 51-00-16 (b) 2 High Frequency Eddy Current (HFEC) Open Hole Inspect 3

2 BACN10HR7CS Nut Remove 4 (a)(g) 2 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y 2 BACW10BP7ACU Washer 2 BACW10BP7APU Washer Oversize the hole to the size listed in table 1 below. (e) 2 Fastener Hole Drill/Ream 5 As given in 757 NDT, Part 6, 51-00-17 and757 NDT, Part 6, 51-00-16 (c) 2 High Frequency Eddy Current (HFEC) Open Hole Inspect 6

BACB30LE7U( ) was installed in production. BACB30LE7U( )X and BACB30LE7U( )Y may have been installed as given in SB 757-54-0015. (a) If any crack is found repeat steps 2 and 3. (b) If any crack is found repeat steps 5 and 6. (c) Not Used (d) The hole through the hinge fitting may be up to 0.457 inch diameter from production. This condition is equivalent to a 0.4526 - 0.4536 inch existing hole diameter. (e) If only one hinge is being oversized and inspected, it is OK to skip the steps that don't apply. (f) Remove one bolt at a time when oversizing and inspecting. (g)

**FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 49 of 78 **BOEING SERVICE BULLETIN 757-54-0049**Table 1 Fastener Hole Sizes
**New Hole Diameter Existing Hole Diameter** 0.4526 - 0.4536 inch Nominal 0.4683 - 0.4693 inch 0.4526 - 0.4536 inch Do Not Oversize Hole 0.4683 - 0.4693 inch

**FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 50 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 51 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.**MORE DATA (f) QTY**  **IDENTIFICATION NAME**  **TASK STEP**  2 BACN10HR7CS Nut Remove 1 (a)(g) 2 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y 2 BACW10BP7ACU Washer 2 BACW10BP7APU Washer Oversize the hole to the size listed in table 1 below. (e) 2 Fastener Hole Drill/Ream 2 As given in 757 NDT, Part 6, 51-00-17 and 757 NDT, Part 6, 51-00-16 (b) 2 High Frequency Eddy Current (HFEC) Open Hole Inspect 3

2 BACN10HR7CS Nut Remove 4 (a)(g) 2 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y 2 BACW10BP7ACU Washer 2 BACW10BP7APU Washer Oversize the hole to the size listed in table 1 below. (e) 2 Fastener Hole Drill/Ream 5 As given in 757 NDT, Part 6, 51-00-17 and 757 NDT, Part 6, 51-00-16 (c) 2 High Frequency Eddy Current (HFEC) Open Hole Inspect 6

BACB30LE7U( ) was installed in production. BACB30LE7U( )X and BACB30LE7U( )Y may have been installed as given in SB 757-54-0015. (a) If any crack is found repeat steps 2 and 3. (b) If any crack is found repeat steps 5 and 6. (c) Not Used (d) The hole through the hinge fitting may be up to 0.457 inch diameter from production. This condition is equivalent to a 0.4526 - 0.4536 inch existing hole diameter. (e) If only one hinge is being oversized and inspected, it is OK to skip the steps that don't apply. (f) Remove one bolt at a time when oversizing and inspecting. (g)

**FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 52 of 78 **BOEING SERVICE BULLETIN 757-54-0049**Table 1 Fastener Hole Sizes
**New Hole Diameter Existing Hole Diameter**  0.4526 - 0.4536 inch Nominal 0.4683 - 0.4693 inch 0.4526 - 0.4536 inch Do Not Oversize Hole 0.4683 - 0.4693 inch

**FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 53 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 54 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine. **MORE DATA (d) QTY**  **IDENTIFICATION NAME**  **TASK STEP**  See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 1

See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque bolt head. Torque to 427-453 in-lbs (target 440 in-lbs). (a) Apply BMS3-33 grease to the threads. (b) Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure. (c) If only one hinge is being worked, it is OK to skip the step that doesn't apply. (d)

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 are used to determine the part numbers used as substitutes.

**FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 55 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA**  **HOLE DIA IDENTIFICATION**  **NAME CODE**  Install special washer under the head of the bolt with countersink towards bolt head and install the plain washer under the nut. See Appendix A. 0.4531 inch BACN10HR7CS Nut A BACB30US7K15X Bolt BACW10BP71APU Plain Washer012N5108-2 Special Washer Install special washer under the head of the bolt with countersink towards bolt head and install the plain washer under the nut. See Appendix A. 0.4688 inch BACN10HR7CS Nut A BACB30US7K15Y Bolt BACW10BP72APU Plain Washer012N5108-4 Special Washer

**FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 56 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 57 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine. **MORE DATA (d) QTY**  **IDENTIFICATION NAME**  **TASK STEP**  See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 1

See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque bolt head. Torque to 427-453 in-lbs (target 440 in-lbs). (a) Apply BMS3-33 grease to the threads. (b) Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure. (c) If only one hinge is being worked, it is OK to skip the step that doesn't apply. (d)

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 are used to determine the part numbers used as substitutes.

**FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 58 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** Install special washer under the head of the bolt with countersink towards bolt head and install the plain washer under the nut. See Appendix A. 0.4531 inch 4 BACN10HR7CS Nut A 4 BACB30US7K15X Bolt 4 BACW10BP71APU Plain Washer 4 012N5108-2 Special Washer Install special washer under the head of the bolt with countersink towards bolt head and install the plain washer under the nut. See Appendix A. 0.4688 inch 4 BACN10HR7CS Nut A 4 BACB30US7K15Y Bolt 4 BACW10BP72APU Plain Washer 4 012N5108-4 Special Washer

**FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 59 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 60 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.**MORE DATA (f) QTY**  **IDENTIFICATION NAME**  **TASK STEP**  2 BACN10HR8CS Nut Remove 1 (a)(g) 2 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y 2 BACW10BP8ACU Washer 2 BACW10BP8APU Washer Oversize the hole to the size listed in table 1 below. (e) 2
- Fastener Hole Drill/Ream 2 As given in 757 NDT, Part 6, 51-00-17 and757 NDT, Part 6, 51-00-16 (b) 2 High Frequency Eddy Current (HFEC) Fastener Holes Inspect 3

2 BACN10HR8CS Nut Remove 4 (a)(g) 2 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y 2 BACW10BP8ACU Washer 2 BACW10BP8APU Washer Oversize the hole to the size listed in table 1 below. (e) 2
- Fastener Hole Drill/Ream 5 As given in 757 NDT, Part 6, 51-00-17 and757 NDT, Part 6, 51-00-16 (c) 2 High Frequency Eddy Current (HFEC) Fastener Holes Inspect 6

BACB30LE8U19 was installed in production. BACB30LE8U19X and BACB30LE8U19Y may have been installed as given in SB 757-54-0015. (a) If any crack is found repeat steps 2 and 3. (b) If any crack is found repeat steps 5 and 6. (c) Not Used (d) The hole through the hinge fitting may be up to 0.521 inch diameter from production. This condition is equivalent to a 0.5151 - 0.5161 inch existing hole diameter. (e) If only one hinge is being oversized and inspected, it is OK to skip the steps that don't apply. (f) Remove one bolt at a time when oversizing and inspecting. (g)

**FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 61 of 78 **BOEING SERVICE BULLETIN 757-54-0049**Table 1 Fastener Hole Sizes
**New Hole Diameter Existing Hole Diameter**  0.5151 - 0.5161 inch Nominal 0.5307 - 0.5317 inch 0.5151 - 0.5161 inch Do Not Oversize Hole 0.5307 - 0.5317 inch

**FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 62 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 63 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.**MORE DATA (f) QTY**  **IDENTIFICATION NAME**  **TASK STEP**  2 BACN10HR8CS Nut Remove 1 (a)(g) 2 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y 2 BACW10BP8ACU Washers 2 BACW10BP8APU Washer Oversize the hole to the size listed in table 1 below. (e) 2
- Fastener Hole Drill/Ream 2 As given in 757 NDT, Part 6, 51-00-17 and 757 NDT, Part 6, 51-00-16 (b) 2 High Frequency Eddy Current (HFEC) Fastener Holes Inspect 3

2 BACN10HR8CS Nut Remove 4 (a)(g) 2 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y 2 BACW10BP8ACU Washers 2 BACW10BP8APU Washer Oversize the hole to the size listed in table 1 below. (e) 2
- Fastener Hole Drill/Ream 5 As given in 757 NDT, Part 6, 51-00-17 and757 NDT, Part 6, 51-00-16 (c) 2 High Frequency Eddy Current (HFEC) Fastener Holes Inspect 6

BACB30LE8U19 was installed in production. BACB30LE8U19X and BACB30LE8U19Y may have been installed as given in SB 757-54-0015. (a) If any crack is found repeat steps 2 and 3. (b) If any crack is found repeat steps 5 and 6. (c) Not Used (d) The hole through the hinge fitting may be up to 0.521 inch diameter from production. This condition is equivalent to a 0.5151 - 0.5161 inch existing hole diameter. (e) If only one hinge is being oversized and inspected, it is OK to skip steps that don't apply. (f) Remove one bolt at a time when oversizing and inspecting. (g)

**FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 64 of 78 **BOEING SERVICE BULLETIN 757-54-0049**Table 1 Fastener Hole Sizes
**New Hole Diameter Existing Hole Diameter** 0.5151 - 0.5161 inch Nominal 0.5307 - 0.5317 inch 0.5151 - 0.5161 inch Do Not Oversize Hole 0.5307 - 0.5317 inch

**FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 65 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.

**FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 66 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (d)**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 1

See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque nut. Torque to 558 - 592 in-lbs (target 575 in-lbs). (a) Apply BMS3-33 grease to the threads. (b) Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure. (c) If only one hinge is being worked, it is OK to skip the step that doesn't apply. (d)

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 are used to determine the part numbers used as substitutes.

**FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 67 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA**  **HOLE DIA IDENTIFICATION**  **NAME CODE**  Install countersunk washer under the head of the bolt with countersink towards bolt head and install the special washer under the nut with the tapered side toward the aft hinge fitting. See Appendix A. 0.5156 inch BACN10HR8CS Nut B BACB30US8K19X Bolt BACW10BP81ACU Countersunk Washer 012N5108-3 Special Washer Install countersunk washer under the head of the bolt with countersink towards bolt head and install the special washer under the nut with the tapered side toward the aft hinge fitting. See Appendix A. 0.5312 inch BACN10HR8CS Nut B BACB30US8K19Y Bolt BACW10BP82ACU Countersunk Washer 012N5108-5 Special Washer

**FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 68 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one engine.

**FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 69 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA (d)**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 1

See fastener table and Appendix A (a) (b) (c) 2
- Fasteners Install (New) 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque nut. Torque to 558 - 592 in-lbs (target 575 in-lbs). (a) Apply BMS3-33 grease to the threads. (b) Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure. (c) If only one hinge is being worked, it is OK to skip the step that doesn't apply. (d)

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 are used to determine the part numbers used as substitutes.

**FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 70 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA**  **HOLE DIA IDENTIFICATION**  **NAME CODE**  Install countersunk washer underthe head of the bolt with countersink towards bolt head and install the special washer under the nut with the tapered side toward the aft hinge fitting. See Appendix A. 0.5156 inch BACN10HR8CS Nut B BACB30US8K19X Bolt BACW10BP81ACU Countersunk Washer 012N5108-3 Special Washer Install countersunk washer underthe head of the bolt with countersink towards bolt head and install the special washer under the nut with the tapered side toward the aft hinge fitting. See Appendix A. 0.5312 inch BACN10HR8CS Nut B BACB30US8K19Y Bolt BACW10BP82ACU Countersunk Washer 012N5108-5 Special Washer

**FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES - FASTENER INSTALLATION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 71 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 13: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 72 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary to remove/install both hinge fittings on the number 1 strut. If only one hinge is being removed/installed on the number 1 strut, then the quantities shown should be halved.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  REMOVAL (b) 4 BACN10HR7CS Nut Remove/Keep 1 4 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y4 BACW10BP7ACU Washer 4 BACW10BP7APU Washer

**FIGURE 13: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 73 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) 4 BACN10HR8CS Nut Remove/Keep 2 4 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y4 BACW10BP8ACU Washer 4 BACW10BP8APU Washer 2 311N5148-1 Thrust Reverser Aft Hinge Fitting Remove/Keep 3

- BMS 5-26 Sealant Remove 4 INSTALLATION Fay surface seal. Refer to SOPM 20-50-19 as an accepted procedure.(c) - BMS 5-45 Sealant Apply 5

(d) 2 Trimmed 311N5148-1 or 311N5148-4 Thrust Reverser Aft Hinge Fitting Install 6

(a) 4 BACN10HR8CS Nut Install 7 4 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y4 BACW10BP8ACU Washer 4 BACW10BP8APU Washer (a) 4 BACN10HR7CS Nut Install 8 4 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y4 BACW10BP7ACU Washer 4 BACW10BP7APU Washer Tighten the fasteners to secure the fittings in place. (a) If existing hardware is undamaged, you can reuse it. (b) Optional to use BMS 5-95 instead of BMS 5-45. (c) Optional to install solid shim made from 2024-T3 aluminum sheet using the same dimensions as the existing laminated shim, if removed. Apply BMS 10-11, Type 1 primer to shim. Fay surface seal shim with BMS 5-45 or BMS 5-95. (d)

**FIGURE 13: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 74 of 78 **BOEING SERVICE BULLETIN 757-54-0049 This Figure applies only to: Group 1, Configuration 1.** 

**FIGURE 14: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 75 of 78 **BOEING SERVICE BULLETIN 757-54-0049**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary to remove/install both hinge fittings on the number 2 strut. If only one hinge is being removed/installed on the number 2 strut, then the quantities shown should be halved.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  REMOVAL (b) 4 BACN10HR7CS Nut Remove/Keep 1 4 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y4 BACW10BP7ACU Washer 4 BACW10BP7APU Washer

**FIGURE 14: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 76 of 78 **BOEING SERVICE BULLETIN 757-54-0049 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) 4 BACN10HR8CS Nut Remove/Keep 2 4 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y4 BACW10BP8ACU Washer 4 BACW10BP8APU Washer 2 311N5148-1 Thrust Reverser Aft Hinge Fitting Remove/Keep 3

- BMS 5-26 Sealant Remove 4 INSTALLATION Fay surface seal. Refer to SOPM 20-50-19 as an accepted procedure.(c) - BMS 5-45 Sealant Apply 5

(d) 2 Trimmed 311N5148-1 or 311N5148-4 Thrust Reverser Aft Hinge Fitting Install 6

(a) 4 BACN10HR8CS Nut Install 7 4 BACB30LE8U19 Bolt BACB30LE8U19X BACB30LE8U19Y4 BACW10BP8ACU Washer 4 BACW10BP8APU Washer (a) 4 BACN10HR7CS Nut Install 8 4 BACB30LE7U( ) Bolt BACB30LE7U( )X BACB30LE7U( )Y4 BACW10BP7ACU Washer 4 BACW10BP7APU Washer Tighten the fasteners to secure the fittings in place. (a) If existing hardware is undamaged, you can reuse it. (b) Optional to use BMS 5-95 instead of BMS 5-45. (c) Optional to install solid shim made from 2024-T3 aluminum sheet using the same dimensions as the existing laminated shim, if removed. Apply BMS 10-11, Type 1 primer to shim. Fay surface seal shim with BMS 5-45 or BMS 5-95. (d)

**FIGURE 14: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - REMOVAL AND INTERIM INSTALLATION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 77 of 78 **BOEING SERVICE BULLETIN 757-54-0049 APPENDIX A: AFT HINGE FITTING FASTENER STACKUP**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 16, 2007 757-54-0049 Revision 2 July 27, 2011 78 of 78 **BOEING SERVICE BULLETIN 757-54-0049**